SAF Technology Insights from Smartenergy
Smartenergy
As the aviation sector accelerates its journey towards decarbonization, the SAF landscape is evolving rapidly—marked by not just policy shifts, but genuine leaps in production technology. In 2025, we're not just talking scale anymore; we're talking transformation. While HEFA (Hydroprocessed Esters and Fatty Acids) continues to dominate current SAF output, the real innovation is happening beyond it. Alcohol-to-jet (ATJ) and Fischer-Tropsch (FT) technologies are maturing, but the spotlight is shifting to next-generation pathways designed for broader feedstock flexibility and lower lifecycle emissions.
SAF producers are moving well beyond proof-of-concept and into a new era of innovation focused on scalability, cost-competitiveness, and feedstock flexibility.
Alcohol-to-Jet (ATJ) Pathway Matures
The ATJ pathway is no longer just an "emerging" option. With isobutanol and ethanol-to-jet routes nearing coxmmercial viability, recent improvements in catalytic conversion efficiency and separation technologies are reducing both CAPEX intensity and OPEX. A standout trend: modular ATJ systems that can be co-located with ethanol plants to repurpose existing infrastructure.
Several tech developers are also working on low-temperature, high-selectivity catalysts to enable smaller-scale production closer to feedstock sources—key for reducing logistics emissions and costs.
Hybrid Pathways and Integration Strategies
A push towards integrated biorefinery models, where SAF is just one output alongside biochemicals and renewable diesel, improving economics and resilience to market fluctuations.
A notable shift in the industry is the blending—or hybridization—of multiple technologies to balance scalability with lifecycle impact. For instance, combining HEFA-derived naphtha with FT-synthesis or using renewable electricity to boost bio-based routes is becoming more common in demo projects.
Process Intensification & Modularization
Efficiency isn’t just about feedstocks—it’s about footprint. Modular SAF production units, especially those focused on waste-to-jet or electrofuels, are gaining traction for regional deployment. These systems cut the time and capital traditionally needed for massive refineries, enabling distributed production closer to feedstock sources and demand centers.
e-SAF / Electrofuels: From Pilot to Pipeline
Power-to-Liquid (PtL) fuels remain a longer-term play, but progress has accelerated. Innovations in solid oxide electrolyzers (SOECs) are enhancing the overall energy efficiency of green hydrogen production—a critical input for PtL SAF.
Moreover, integration of direct air capture (DAC) with fuel synthesis units is gaining traction, as developers seek to streamline CO₂ sourcing while maximizing lifecycle GHG reductions. The focus is shifting from individual components to system-level optimization, with digital twins and AI-powered process controls playing a bigger role in early deployments.
Carbon Capture Integration: From Concept to Component
One of the most exciting shifts is the embedding of direct air capture (DAC) and point-source carbon capture within SAF production frameworks. Captured CO₂, when combined with green hydrogen, can serve as a reliable carbon source for synthetic fuels—radically reducing reliance on biomass and solving land-use conflicts.
What was once a moonshot is now entering engineering-phase discussions. The key challenge? Ensuring a clean and scalable hydrogen supply chain—one that aligns with evolving EU and U.S. SAF blending mandates without shifting emissions upstream.
Smartenergy’s e-SAF Project
Smartenergy is spearheading innovative eSAF projects in Europe, aiming to decarbonize the aviation sector by producing synthetic jet fuel using green hydrogen and captured CO2.
Smartenergy’s strategy involves generating green hydrogen through electrolysis powered by dedicated solar photovoltaic (PV) and wind energy installations. This green hydrogen is then combined with CO₂ captured from waste-to-energy plants (and/or other biogenci CO2 sources) to produce eSAF via the Fischer-Tropsch (FT) synthesis process.
One of Smartenergy's flagship initiatives is the Galileu Green H₂ Valley, located in Vila Franca de Xira, Portugal. The proximity to industrial CO₂ sources and aviation fuel offtakers enhances the project's efficiency and sustainability. The Galileu Green H₂ Valley has received recognition for its innovative approach to decarbonizing both the cement and aviation industries.
Smartenergy's integrated approach to eSAF production, combining renewable energy sources with carbon capture technologies, positions it as a leader in sustainable aviation fuel development. By leveraging Portugal's renewable energy potential and industrial infrastructure, Smartenergy aims to contribute significantly to the decarbonization of the aviation sector.
Looking Ahead: Integration and Interoperability
In 2025 and beyond, the winning SAF technologies will likely be those that play well with others. Hybrid systems—blending bio-based feedstocks with CO₂-derived inputs, or coupling electrofuels with waste heat recovery—will define the next wave of scalable, sustainable solutions. Cross-sector partnerships (think aviation + energy + tech) are no longer experimental; they’re essential.
One of the most interesting dynamics in today’s SAF ecosystem is the inversion of the traditional cycle: technology is outpacing policy. With ASTM approvals for new pathways expected to accelerate and lifecycle analysis tools becoming more sophisticated, producers who can stay nimble—technically and commercially—will be best positioned to lead in a policy environment that is still catching up.